Automatic packaging apparatus

ABSTRACT

An automatic packaging apparatus for rapidly, accurately and gently packing randomly oriented objects, such as fresh fruits and vegetables, into compartmented trays.

United States Patent [72] Inventors Lloyd E. Allen l'larlingen, Tex.; Lawrence W. McCracken, Morristown, NJ.

[21] Appl. No. 832,388

[22] Filed June 11, 1969 [45] Patented Mar. 23, 1971 [731 Assignees Tri-Pak Machinery Services Inc.;

Keves Fibre Company a fractional part interest to each [54] AUTOMATIC PACKAGING APPARATUS 9 Claims, 5 Drawing Figs.

[52] US. Cl 53/160 51 Int. Cl B65b 35/44 [50] Field ofSearch 53/160 [56] References Cited UNITED STATES PATENTS 2,542,330 2/ l 951 Henderson et al 53/160 3,225,513 12/1965 Ehe 53/160 3,314,212 4/1967 Pcppler 53/160X 3,470,674 10/1969 Madonia 53/ l 60X Primary Examiner-Travis S. McGehee Attorney-Pravel, Wilson and Matthews ABSTRACT: An automatic packaging apparatus for rapidly, accurately and gently packing randomly oriented objects, such as fresh fruits and vegetables, into compartmented trays.

AUTOMATIC PACKAGING APPARATUS BACKGROUND OF THE INVENTION protection against bruising, breaking or other damage during transportation. Such manual packaging has been relatively slow with the productivity being dependent on the number and skill of the workers, but because of the many problems in attempting to package such objects with machinery, the manual packaging has continued through the years.

SUMMARY OF THE INVENTION The present invention relates to automatic packaging apparatuswhich is particularly suitable for packing generally symmetrical or round objects, such as tomatoes, apples, pears, peaches, plums, potatoes and Christmas tree ornaments. The apparatus is so constructed that it can'receive the objects from a sizer or other source in randomly oriented fashion and group them so as to fill conventional multipocket trays which are moving continuously. The apparatusmoves and otherwise handles the objects gently enough so that even soft objects such as ripe tomatoes can be packaged without bruising or breaking them. Also, fragile objects, if generally symmetrical or round in shape, such as some Christmas tree ornaments, may be packaged with this apparatus.

Thus, the apparatus of this invention rapidly, accurately and gently packages such objects into multipocket trays, whereby a minimum of manual handling of the objects is required.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a plan view of the preferred form of the apparatus of this invention;

FIG. 2 is an elevation of the apparatus of this invention;

FIG. 3 is a partial sectional view taken on line 3-3 of FIG. 1;

FIG. 4 is a schematic electrical wiring diagram illustrating the electrical circuit for controlling the operation of the apparatus of this invention; and

FIG. 5 is an elevation of the control panel for controlling he the operation of the apparatus of this invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS In the drawings, the letter F designates generally the object or fruit conveyor F which is disposed above a tray conveyor T which, as will be more fully explained, includes a forward tray conveyor T-l and a rear tray conveyor T-2. A feeding or cross transfer conveyor C feeds or delivers fruit such as tomatoes of other round or symmetrical objects to the fruit or object conveyor F. The fruit or other objects 10 are randomly fed on a constant conveyor such as the cross transfer conveyor C to the moving conveyor F. As will be explained more in detail, the feeding of such objects 10 is controlled, even though there is a random distribution and feeding from the conveyor C to the conveyor F, so as to maintain the conveyor F full of fruit or other objects 10 at the discharge end of the conveyor F. Conventional multipocket trays 12 are fed below the fruit conveyor F on the tray conveyor T at a rate to receive the fruit or other objects 10 as they are discharged from the forward end of the fruit conveyor F, whereby the empty pockets 12a in each of the trays 12 are filled while the trays 12 are continuously moved non the tray conveyor T.

Considering the invention more in detail, the fruit or object conveyor F may be a conventional belt conveyor having an endless belt 15 which is mounted in any conventional manner v upon a rear roller or pulley l6, and a forward or discharge roller or pulley 17. The belt 15 is driven so as to move its upper surface from left to right as viewed in FIGS. 1 and 2 by means of a motor 18 or any other suitable power means con nected to the forward or discharge pulley or roller 17. The conveyor F preferably has longitudinally extending retaining sides 19 which confine the fruit or other objects it) as they are being moved longitudinally along the upper surface of the conveyor belt 15 to discharge end of the conveyor F.

The tray conveyor T may be formed as a single conveyor, but in the preferred form of the invention, such conveyor T is formed by a rear conveyor T-2 and a forward conveyor T-l which move at different speeds. Each conveyor has a conventional endless belt on suitable end pulleys. in FIG. 2, the tray conveyor T-l is shown as having a conveyor belt 22 which is disposed between sides 23 for thereby moving and guiding the trays l2 longitudinally thereon from left to right as viewed in FIGS. 1 and 2. The trays 12 are preferably stacked in proximity to the reartray conveyor T-2, which stack is illustrated at A in FIGS. 1 and 2. The trays 12 are placed on the belt of the conveyor T-2 by hand or any other suitable means so that they are longitudinally positioned thereon and are in abutment with each other. The tray conveyor T-2 and also the tray conveyor T-l are operated by a motor 25 which is connected by a chain 26 or any other suitable means to drive wheel 27 at the forward end of the endless belt for the conveyor T-2. The drive wheel 27 is preferably a pulley having a belt 27a therewith which fits over a belt 28 on the rear end of the forward tray conveyor T-l. The belt of the rear conveyor T-2 is preferably driven at a speed which si approximately 15 percent faster than the speed at which the belt of the forward tray conveyor T-l is fed and therefore the pulley 28 is smaller in diameter than the pulley 27 as illustrated in FIG. 2 to such difference in speeds. By reason of the faster conveyor R T-2 feeding the trays to the slower conveyors T-l, the trays 12 are caused to abut each other and are held in such abutment as they are moved into position below the discharge end of the fruit conveyor F.

As illustrated in FIG. 2, it is preferable to incline the tray conveyor T slightly upwardly in the direction of the movement of the trays 12 as they are being filled by the fruit or other objects 10. Such angle of inclination facilitates the rolling of the fruit or other objects 10 slightly backwardly and downwardly as they are discharged from the conveyor F into the trays 12. As illustrated in FIG. 2, the discharge pulley or roller 17 on the forward end of the conveyor F is of a smaller diameter than the fruit or other objects 10 which are being packaged, and the bottom of such pulley 17 is as close as possible to the top of the trays 12 as they pass below such pulley 17 so as to more readily direct the fruit or other object 10 into the pockets 12a of the trays 12. In the usual instance, the clearance between the top of the trays l2 and the bottom of the discharge conveyor pulley 17 will be not more than about three-sixteenths of an inch and this facilitates the rolling action as illustrated in FIG. 2. Actually, the fruit or other objects coming off of the conveyor F will bump into the fruit that has preceded it and which is already in-the tray 12 and thus, the discharging fruit will deflect backward and downward into the only available resting place, a tray pocket 12a to thereby assure the proper positioning and filling of such trays 12.

It should also be noted that the width of the conveyors F and T are such that the number of fruit 10 which occupy the width of the fruit conveyor F corresponds with the width of the trays l2, and as will be explained, with the apparatus of this invention, the discharge end of the conveyor F is maintained full of fruit during the loading operation so that there are always enough fruit to fill the pockets 12a of the trays 12 as they are fed below the discharge end of the fruit conveyor F.

The fruit or other objects 10 may be fed to the conveyor F by any suitable means, but normally, in a typical packing installation wherein fruit is to 83 packaged, the fruit or other ob jects 10 are fed from a cross transfer conveyor C, as previously noted. The cross transfer conveyor C may be a conventional conveyor having a belt 30 (FIGS. 1 and 3) and a forward or discharge roller or pulley 31. The top of the conveyor belt 30 moves from left to right as viewed in FIG. 3.

Preferably, the conveyor C is operated at a constant speed and the fruit or other objects are fed from a conventional fruit sizing device or any other suitable source. Normally, the objects 10 are randomly spaced as indicated schematically in the drawing. For the purpose of controlling the operation of the apparatus so as to properly distribute the fruit or other objects 10 on the fruit conveyor F from the conveyor C, the conveyor C has a plurality of longitudinally extending guides 35 which serve to channel the fruit or other objects 10 to switches S-l through 8-6. The switches S-l through 8-6 are supported by any suitable framework or mounting 37 so that each of the objects or fruit 10 which pass under the switches S-l through S-6 actuates one of such switches for a purpose to be hereinafter explained. It is to be noted that the side 19 of the conveyor F which is adjacent to the conveyor C has an inclined surface 40 to allow for a gentle rolling of the fruit or other objects 10 from the conveyor C onto the conveyor F. As the fruit or other objects 10 are discharged from the conveyor C, they actually roll until they reach the opposite side of the conveyor F or until they engage a fruit or other object which is already on the conveyor F so thatthere is a complete lateral and longitudinal filling of the fruit conveyor F as the fruit or other objects 10 are discharged from the conveyor C. As will be explained, the ratio of the feeding of the fruit or other objects 10 to the movement of the fruit conveyor F is regulated automatically so that the conveyor F is thus filled by the fruit or other objects for its full length from the point of filling at the cross transfer conveyor C to the discharge end at the forward pulley 17. The fruit or other objects 10 thus fill the conveyor F in a single layer at the discharge end for thereby providing a constant source of fruit for filling the empty pockets 12a of the trays as they pass thereunder.

Referring now to the electrical diagram illustrated in FIG. 4, and also the control panel P which is used in conjunction therewith, one type of electrical speed control for the apparatus is illustrated, although it will be understood that the invention is not limited thereto. For example, the number of the switches 8-! through 8-6 is merely exemplary since the number may be varied depending upon the conditions, volume of objects being handled and the size of the apparatus.

The fruit conveyor motor 18 is electrically controlled by a silicon control rectifier (SCR) motor control 50 of conventional construction, and having a potentiometer 50a therewith. The motor 25 for the tray conveyor T likewise is electrically controlled and connected to a silicon control rectifier (SCR) motor control 51 which has a potentiometer 51a therewith. With the fruit conveyor F completely filled with fruit in a single layer and with the tray conveyor T having trays positionedthereon in abutting relationship for receiving the fruit or other objects 10 in the pockets 120, the speeds of the conveyors T and F are initially adjusted so that there will always be the exact number of the pockets 12aavailable for the number of the fruit or other objects 10 discharged from the conveyor F. Such ratio speed may be obtained by the control of the potentiometers 50a and 51a which are on the panel P. This is done when the mode switch 52 is in the manual position and when the power switch 53 is on. The relative ratio of the speeds of the fruit conveyor F and the tray conveyor T may be determined empirically or mathematically. For example, if one of the trays 12 is 18 inches long and holds 20 fruit or other objects and the fruit conveyor F holds 20 fruit per foot, the tray conveyor T would have to move one and one-half times as fast as the fruit conveyor F.

To maintain the fruit conveyor F full of fruit at all times while the fruit or other objects 10 are being fed at random intervals from the cross transfer conveyor C, the electrical system as illustrated in FIG. 4 controls the speed of the fruit conveyor F in accordance with the rate of delivery or feeding of the fruit or objects 10 from the cross transfer conveyor C. The preset ratio of speed between the conveyors F and T is maintained even though the speeds thereof are both altered as will be more evident hereinafter.

The speed control is accomplished in the preferred form of the invention as illustrated in FIG. 4 by a digital-rate-toanalog-voltage conversion. The generated analog voltage is directly proportional to the rate at which the fruit or other objects l0 transfer from the conveyor C to the fruit conveyor F. Such voltage is used to control the cyclic firing point of the two SCR motor controls 50 and 51 so as to thereby control the speed of operation of the motors 18 and 25. It will be understood that the motors l8 and 25 are direct current motors in the preferred form of the invention.

As shown in FIG. 4, each of the switches S-l through 8-6 is in an electrical circuit with pulse generating means, each of which includes a capacitor C-l through C-6, respectively. The switches 5-! through S-6 are single-pole, double-throw switches and they are shown in their normally closed position where they remain until they are actuated. When a fruit or other object 10 actuates each switch 8-] through 8-6, the associated capacitor C-l through C- 6 quickly charges, in a few milliseconds, to approximately 12 volts which is supplied from the power supply 60 through the terminal 61 and the variable resistor 62. As soon as the fruit releases the particular switch which is actuated, it returns to its normally closed position so as to discharge the capacitor associated therewith and thus reset such capacitor for the next charge or pulse. When the switch returns to its normally closed position, the capacitor is then connected so as to form a pulse which is transmitted to an operational amplifier 63 of conventional construction and which is connected electrically with a capacitor 64, a resistor 65, and a diode 66. The amplifier 63 together with the capacitor 64, resistor 65 and diode 66 to serve to sum up or add the current that make up the various pulses coming from the capacitor C-l through C-6 and they are converted into a voltage that is directly proportional to the number of pulses per unit of time. The capacitor 64 establishes the time base during which the pulse rate is averaged. The output voltage from the amplifier 63 is amplified and inverted by transistor 67 and such output is then used as a trigger voltage to vary the conduction angle of the silicon controlled rectifiers 50 and 51.

The net result of such circuitry is that the speed of the two motors 18 and 25 driving the fruit conveyor F and the tray conveyor T, respectively, varies directly in proportion to the number of the fruit or other objects 10 coming onto the fruit conveyor F each second.

In addition to the basic circuit described above, the circuit also preferably includes a minimum speed rheostat or bias control 70 and a size compensating rheostat 62, which are also on the panel P. A light bulb 72 is also preferably included in the circuit and is shown on the panel 72 for visually indicating the pulses so as to indicate to the operator the input rate of the fruit or other objects being fed to the fruit conveyor F. The size compensation provided by the potentiometer or rheostat 62, so as to compensate for fruit or objects 10 of different sizes, is accomplished emperically by the operator when it is apparent that larger objects are arriving from the conveyor C as compared to the objects previously fed into the system. It is believed evident that larger fruit or objects arriving in the same quantity per unit of time will require more travel of the belt 15 than the arrival of smaller fruit in the same quantity per unit of time. By adjusting the potentiometer 62, the input voltage to the capacitors is adjusted so as to ultimately vary the output range of the amplifier 63. Thus, if the bias voltage is reduced by the potentiometer 62, the same number of pulses per second from the capacitors C-l through C-6 will not change the speeds of the conveyors F and T as much as if the bias voltage is set higher.

In the operation or use of the apparatus of this invention, the mode switch 52 is turned to the manual position and then the power switch 53 is turned on. The speeds of the fruit and tray conveyors are then set to the proper ratio and at their maximum speeds for maximum packing of fruit into the trays 12. This is accomplished by adjusting the potentiometers 50a and 51a, as previously explained.

Thereafter, the mode switch is changed to the 143 position. The operator then sets the potentiometer 70 for the bias ,control to the minimum speed at which the conveyors F and T will operate. As the fruit or other objects are being fed to the conveyor F, the operator watches the fruit or other objects 10 and adjusts the potentiometer 62 to compensate forthe size of such fruit or other objects. As the rate of movement or feeding of the objects 10 increases, thespeed of the fruit conveyor F and the tray conveyor T automatically increases until they are accepting the proper amount of fruit for filling the trays 12. It will be understood of course that no trays 12 are necessary until the fruit has completely filled the fruit conveyor F to the discharge end at the roller 17. When his desired to empty the fruit conveyor F, the mode switch is turned to manual and then the belts on the conveyors F and T will move at their maximum speeds to finish the feeding and packaging of the fruit or other objects into the trays 12. v

The foregoing disclosure and-description of the invention are illustrative and explanatory thereof, and various changes in the size, shape, and materials as well as in the details of the illustrated construction may be made without departing from the spirit of the invention.

We claim: I Y

1. Packaging apparatus for rapidly, gently and accurately packaging objects which are generally-symmetrical in shape into multipocket trays, comprising: a

a. an object conveyor adapted to convey a plurality of objects which are generally symmetrical in shape and of approximately the same size;

b. a tray conveyor for continuously conveying a plurality of multipocket trays beneath the discharge end of said object conveyor for receivingjobjects from said object 'conveyor as they are discharged therefrom;

c. means for setting the speeds of said object conveyor and said tray conveyor relative to each other for continuously discharging the quantity of objectsfrom the discharge end of said object conveyor to continuously fill substantially all of the pockets in the-trays. moving continuously relative thereto; I

d. feeding means for feeding the objects to said object conveyor; and

e. means for regulating the speed of said object conveyor relative to the number of objects being fed thereto by said feeding means in a given unit of time for maintaining the discharge end of said object conveyor substantially full of the objects at all times during the filling of the trays of the tray conveyor with the objects discharged from the object conveyor. 1

2. The structure set forth in claim 1, including:

means for simultaneously regulating the speeds of said object conveyor and said tray conveyor with respect to the rate at which the objects are fed from said feeding means to said object conveyor for the filling of the trays on the tray conveyor with the objects discharged from the object conveyor.

3. The structure set froth in claim 1, wherein:

a. said tray conveyor is disposed below and in'longitudinal alignment with said object conveyor;

b. said tray conveyor includes a forward tray conveyor and a rear tray conveyor;

c. said forward tray conveyor extending beneath and forwardly of said discharge endjof said object conveyor; and

d. means for driving said rear tray conveyor at a slightly greater speedthan said forward tray conveyor to maintain trays moving thereon in abutment with each other.

4. The structure set forth in claim .1, including:

means for adjusting the rate of feeding of the objects from said feeding means to compensate for different sizes of objects being fed to the object conveyor.

5. The structure set forth in claim 1, wherein said feeding means includes:

a feeding conveyor disposed substantially perpendicular to said object conveyor at an area remote from said discharge end of said object conveyor for receiving the objects at random spacing thereon. 6. The structure set forth In cla m 2, wherein;

a. said feeding means includes a feeding conveyor disposed substantially perpendicularly to said object conveyor at an area remote from said discharge end of said object conveyor for receiving theobjects at random spacing thereon from a sizer or the like;

. said means for setting the speeds of said object conveyor and said tray conveyor including direct current motors and silicon control rectifiers for controlling the level of the voltage to each of said motors; and

c. said means for simultaneously regulating the speeds of said object conveyor and said tray conveyor with respect to the rate at which the objects are fed from said feeding conveyor includes:

1. a plurality of sensor switches disposed across the discharge end of said feeding conveyor;

2. said sensor switches being in an electrical circuit with pulse generating means. for generating pulses upon each closing of a sensor switch;'and

3. said silicon control rectifie'rs and motors being in said electrical circuit and having means therewith for triggering said rectifiers in response to a predetermined rate of pulses from the pulse generating means.

7. The structure set froth in claim 6, including:

guide means on said feeding conveyor for guiding objects as they are moved on said feeding conveyor to said sensor switches for assuring that only one switch is actuated by each object.

8. The structure set forth in claim 1, wherein:

a. said tray conveyor is disposed below and in longitudinal alignment with said object conveyor; and

b. said tray conveyor is inclinedupwardly from the rear end to the forward end thereof to assist in maintaining the trays thereon in abutment with each other.

9. The structure set forth in claim 1, wherein:

a. said object conveyor includes a conveyor belt having a belt pulley at its discharge end which is smaller in diameter than the objects conveyed thereon;

b. the discharge end of said conveyor belt constituting the terminal end of said conveyor; and

c. the space between the lower surface-of said discharge end of said object conveyor and the upper surface of the trays on said tray conveyor is less than the thickness of the objects conveyed by said object to said tray conveyor. 

1. Packaging apparatus for rapidly, gently and accurately packaging objects which are generally symmetrical in shape into multipocket trays, comprising: a. an object conveyor adapted to convey a plurality of objects which are generally symmetrical in shape and of approximately the same size; b. a tray conveyor for continuously conveying a plurality of multipocket trays beneath the discharge end of said object conveyor for receiving objects from said object conveyor as they are discharged therefrom; c. meanS for setting the speeds of said object conveyor and said tray conveyor relative to each other for continuously discharging the quantity of objects from the discharge end of said object conveyor to continuously fill substantially all of the pockets in the trays moving continuously relative thereto; d. feeding means for feeding the objects to said object conveyor; and e. means for regulating the speed of said object conveyor relative to the number of objects being fed thereto by said feeding means in a given unit of time for maintaining the discharge end of said object conveyor substantially full of the objects at all times during the filling of the trays of the tray conveyor with the objects discharged from the object conveyor.
 2. The structure set forth in claim 1, including: means for simultaneously regulating the speeds of said object conveyor and said tray conveyor with respect to the rate at which the objects are fed from said feeding means to said object conveyor for the filling of the trays on the tray conveyor with the objects discharged from the object conveyor.
 2. said sensor switches being in an electrical circuit with pulse generating means for generating pulses upon each closing of a sensor switch; and
 3. said silicon control rectifiers and motors being in said electrical circuit and having means therewith for triggering said rectifiers in response to a predetermined rate of pulses from the pulse generating means.
 3. The structure set froth in claim 1, wherein: a. said tray conveyor is disposed below and in longitudinal alignment with said object conveyor; b. said tray conveyor includes a forward tray conveyor and a rear tray conveyor; c. said forward tray conveyor extending beneath and forwardly of said discharge end of said object conveyor; and d. means for driving said rear tray conveyor at a slightly greater speed than said forward tray conveyor to maintain trays moving thereon in abutment with each other.
 4. The structure set forth in claim 1, including: means for adjusting the rate of feeding of the objects from said feeding means to compensate for different sizes of objects being fed to the object conveyor.
 5. The structure set forth in claim 1, wherein said feeding means includes: a feeding conveyor disposed substantially perpendicular to said object conveyor at an area remote from said discharge end of said object conveyor for receiving the objects at random spacing thereon.
 6. The structure set forth in claim 2, wherein; a. said feeding means includes a feeding conveyor disposed substantially perpendicularly to said object conveyor at an area remote from said discharge end of said object conveyor for receiving the objects at random spacing thereon from a sizer or the like; b. said means for setting the speeds of said object conveyor and said tray conveyor including direct current motors and silicon control rectifiers for controlling the level of the voltage to each of said motors; and c. said means for simultaneously regulating the speeds of said object conveyor and said tray conveyor with respect to the rate at which the objects are fed from said feeding conveyor includes:
 7. The structure set froth in claim 6, including: guide means on said feeding conveyor for guiding objects as they are moved on said feeding conveyor to said sensor switches for assuring that only one switch is actuated by each object.
 8. The structure set forth in claim 1, wherein: a. said tray conveyor is disposed below and in longitudinal alignment with said object conveyor; and b. said tray conveyor is inclined upwardly from the rear end to the forward end thereof to assist in maintaining the trays thereon in abutment with each other.
 9. The structure set forth in claim 1, wherein: a. said object conveyor includes a conveyor belt having a belt pulley at its discharge end which is smaller in diameter than the objects conveyed thereon; b. the discharge end of said conveyor belt constituting the terminal end of said conveyor; and c. the space between the lower surface of said discharge end of said object conveyor and the upper surface of the trays on said tray conveyor is less than the thickness of the objects conveyed by said object to said tray conveyor. 